Installation and Setup Instructions

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1 Installation and Setup Instructions Model: Version: Master MR160P Date of issue: 27 January 2015 Compac Industries Ltd. 52 Walls Road. Penrose. Auckland New Zealand. PO Box Penrose. Auckland New Zealand. Tel: Fax: info@compac.co.nz

2 Contents Contents Conditions of use Footprint Optional Flexi Coupling Static Electricity Precautions Pre-installation Check Installation Comms Dip-switch settings Standard Pump Comms Setting Gilbarco Pump comms Setting Triac Dip-switches Electrical Connections Dispensing Hoses and Nozzles Breakaways Setting up the C Configuration Codes Parameter Switch Settings K-Factor Switch Settings Calibration (K-Factor) Setting the K-Factor Sealing the K-Factor switch Standalone Operation Pump Controller Spare Fuses Precautions if Using Generator Power Error Messages MR160P Spare Parts Product Details Contact Details Notes Revision History Page 2 of 18

3 1. Conditions of use Read this manual completely before working on or making adjustments to the Compac equipment. Compac Industries Limited accepts no liability for personal injury or property damage resulting from working on or adjusting this unit incorrectly or without authorisation. Along with any warnings, instructions, and procedures in this manual, you should also observe any other common sense procedures that are generally applicable to equipment of this type. Failure to comply with any warnings, instructions, procedures, or any other common sense procedures may result in injury, equipment damage, property damage, or poor performance of the Compac equipment The major hazard involved with installing and operating the unit is electrical shock. This hazard can be avoided if you adhere to the procedures in this manual and exercise all due care. Compac Industries Limited accepts no liability for direct, indirect, incidental, special, or consequential damages resulting from failure to follow any warnings, instructions, and procedures in this manual, or any other common sense procedures generally applicable to equipment of this type. The foregoing limitation extends to damages to person or property caused by the unit or damages resulting from the inability to use the unit including loss of profits, loss of products, loss of power supply, the cost of arranging an alternative power supply, and loss of time, whether incurred by the user or their employees, the installer, the commissioner, a service technician, or any third party. Compac Industries Limited reserves the right to change the specifications of its products or the information in this manual without necessarily notifying its users. Variations in installation and operating conditions may affect the unit's performance. Compac Industries Limited has no control over each installation's unique operating environment. Hence, Compac Industries Limited makes no representations or warranties concerning the performance of the unit under the actual operating conditions prevailing at the installation. A technical expert of your choosing should validate all operating parameters for each application. Compac Industries Limited has made every effort to explain all servicing procedures, warnings, and safety precautions as clearly and completely as possible. However, due to the range of operating environments, it is not possible to anticipate every issue that may arise. This manual is intended to provide general guidance. For specific guidance and technical support, contact your authorised Compac supplier, using the contact details in the Product Identification section Only parts supplied by or approved by Compac may be used and no unauthorised modifications to the hardware of software may be made. The use of non-approved parts or modifications will void all warranties and approvals. The use of non-approved parts or modifications may also constitute a safety hazard. Information in this manual shall not be deemed a warranty, representation, or guarantee. For warranty provisions applicable to this unit, please refer to the warranty provided by the supplier. Unless otherwise noted, references to brand names, product names, or trademarks constitute the intellectual property of the owner thereof. Subject to your right to use the unit, Compac does not convey any right, title, or interest in its intellectual property, including and without limitation, its patents, copyrights, and know-how. Every effort has been made to ensure the accuracy of this document. However, it may contain technical inaccuracies or typographical errors. Compac Industries Limited assumes no responsibility for and disclaims all liability of such inaccuracies, errors or omissions in this publication. Page 3 of 18

4 2. Footprint Outlet size: 1 ¼ BSP female socket. Outlet is approximately 680mm above the base. Page 4 of 18

5 Page 5 of 18

6 2.1 Optional Flexi Coupling 3. Static Electricity Precautions Electronic components used are sensitive to static. Please take anti-static precautions. An anti-static wrist strap should be worn and connected correctly when working on any electronic equipment. If an anti-static wrist strap is unavailable, or in an emergency, hold onto an earthed part of the pump/dispenser frame whilst working on the equipment. This is not a recommended alternative to wearing an anti-static wrist strap. Note: Compac Industries Limited reserves the right to refuse to accept any circuit boards returned, if proper anti-static precautions have not been taken. 4. Pre-installation Check Once the pump is received on site, check that no damage has occurred while in transit in particular, damage to electronics due to vibration or jarring. All terminals and plugs should be checked, including IC chips, to ensure they are securely in place. 5. Installation Installation should be in accordance with local regulations. To obtain maximum flow on a self contained pump, observe the following guidelines: 1. Pumps must not be subject to any head pressure. Design your installation to eliminate any possibility of this occurring. 2. Total length of horizontal piping between tank and pump should be no longer than 18 metres. Use galvanised steel or approved non-metallic pipe and fittings. 3. The unit contains two pumps each with an 1 ½ flanged inlet. It is recommended that each inlet is supplied from the tank by a separate 2 pipe. If using a single supply pipe and a tee joint, ensure that the size of the pipe and tee joint will be sufficient to provide adequate flow otherwise pump performance will suffer. If a tee joint is used, check valves must be installed before each pump inlet. Note: Ensure you remove the bung from the pump inlet before connecting the pipe. 4. Pipe must slope up from the tank to the pump (approximately 15 mm per metre). Pipe should be straight and supported along its length. 5. All horizontal piping must be buried at least 450mm below ground level. 6. The area under the pumping unit(s) must be filled with sand or dirt as far up the suction line as possible. Use water to pack the sand or dirt when put in place. Page 6 of 18

7 7. Avoid asphalt drive surfaces covering the piping. Asphalt increases heat absorption causing vapour lock. 8. Static lift must not exceed 3 metres (vertical distance from the product level in the tank to the centre of the pump unit). 9. To absorb ground movement from settling of the tank, frost heaving of the ground or pump island settling, a swing joint must be used in the supply line at the tank and directly underneath the dispenser. Three additional directional changes using elbows are permitted. 10. Piping must hold a 3.4 Bar (50PSI) pressure test for a minimum of 10 minutes. 11. It is recommended that a vertical, in-line check valve be installed underneath the pump. 12. The dispensing equipment shall be installed to prevent the delivery hose from contacting the ground when not in use. 13. A Check Valve must be installed at the tank end of the suction pipe on the top of the tank in a serviceable location. Many clients install an extra check valve at the inlet to the pump. It is important neither of the check valves interfere with the flow of fuel. They must be adequately sized Refer to the footprint drawings for pump installation details. Where local regulations require a sump to be fitted: a. Sumps must be provided at all dispenser installations with secondary containment pipework and at all new installations; and b. at all sites with sumps, dispensers should be installed with a liquid level detection device fitted in the sump that will raise an alarm if liquid is detected in the base of the sump. The pump inlet must not be pressurised at any time. This will cause fuel to flow from the air eliminator. Unregulated connection to an above ground tank will cause pressurisation. For above ground tanks a regulator valve such as a Tokheim valve or similar device MUST be used so that the inlet of the pump cannot become pressurised at any time. approvals. The air switch is not to be disconnected. Disconnection will void NSC and TMU Page 7 of 18

8 6. Comms Dip-switch settings 6.1 Standard Pump Comms Setting (Dipswitch SW3) 1-ON 2-OFF 3-ON 4-OFF These are factory set to the standard setting unless ordered otherwise.eg Gilbarco. 6.2 Gilbarco Pump comms Setting (Special software and interface board required) 1-OFF 2-ON 3-OFF 4-ON 7. Triac Dip-switches Important note: Great care should be taken not to accidentally change the setting of these switches while working in the Flame-proof box. Operating the unit with these incorrectly set can result in damage to the C4000 Power Supply or incorrect operation of the triacs. These switches are set in the factory and should not be changed. If they are accidentally changed these are the correct settings for Master / Premier Pump applications.note: They are 3 position switches Pump (Motor triac fitted) SW1 1 SW2 1 SW4 Centre Page 8 of 18

9 8. Electrical Connections Prior to pump installation ensure that there is at least a two-metre tail on both the incoming underground mains supply cable and comms cable (if comms enabled). These cables are terminated at the C4000 power supply, which is housed in the flameproof enclosure located in the bottom of the pump, behind the door. Mains power wiring should be rated for a maximum current draw of 10 A rms at V ac. The incoming cables are terminated as shown in the following picture. Refer to AS/NZS for appropriate cabling. Note: All cables entering the power supply must be glanded with approved 20mm flameproof glands. Note: Comms cable is not intrinsically safe. Note: Pump comm s connect to pump controller such as DCA, Communicator Controller etc. (option). When replacing the lid of the flameproof enclosure, ensure the sealing O ring is in place. COMMS + ve - ve INCOMING MAINS Neutral Phase Earth Page 9 of 18

10 9. Dispensing Hoses and Nozzles The unit may or may not be supplied with dispensing hose and nozzle assemblies. If customer supplied hose assemblies, pylons, reels, safe breaks and nozzles are used they must comply with the requirements outlined in AS/NZS Breakaways For all dispensers fitted with breakaways, ensure the breakaway is installed between the nozzle and the high-mast or pylon (if fitted). Any breakaways that have been subject to a break-away situation should be inspected and refitted or replaced in accordance with the original manufacturer s instructions. 10. Setting up the C4000 Once the pump is connected on site, the final setup check and calibration to complete the installation must be carried out, using the Parameter Switch and Calibration (K-Factor) Switch. These switches are found on the C4000 Microprocessor Board which is housed in a metal enclosure located on the left front of the unit below the display panel 10.1 Configuration Codes The configuration code has been set at Compac and should not be changed In the event of it being lost and having to be re-entered the configuration is written on the yellow label on the C4000 processor board cover 10.2 Parameter Switch Settings Setting the Pump Number This must be set at the pump, for each hose, so that communications with a controller can take place. The location of this switch is shown in the diagram below. Depress the Parameter Switch nine (9) or more times until the message 'PnA XX' appears in the litres display window. When the switch is pressed again 'Pnb XX ' will appear on the display. These two options will toggle each time the switch is pressed. To alter either of the pump numbers, press and hold the Parameter Switch when the pump number to be altered appears on the display. This number will then increment. The switch should be released when the desired pump number is displayed. The value of the displayed number will then be stored in the C4000 memory as the pump number for that hose. NOTE: For a single hose only Pn will appear Page 10 of 18

11 Setting the Price Using the Parameter Switch, follow the chart to set the price for the hose(s) in question. Step ACTION RESULT 1 Ensure that the nozzle is hung up Dispenser in idle state 2 Press and Hold the Parameter switch until the Price per litre is displayed. The price for side A is shown as PX.XXX on the litres display and PrA is displayed on the money display. 3 Press and hold the Parameter switch. A digit, of the displayed Price per litre, will begin to increment. 4 When the digit is correct, release the Parameter switch. 5 Repeat steps 3 and 4 for each digit of the Price per litre. 6 Press and release the Parameter switch 8 or more times in quick succession 7 Repeat steps 3 to 5 above. NOTE: the C4000 will reset itself if the Parameter switch is left for more than 60 seconds. Continue for Dual hose units The price for side B is shown as PX.XXX on the litres display and Prb is displayed on the money display. Page 11 of 18

12 10.3 K-Factor Switch Settings K-Factor, and other various configuration settings, are set via this switch. The position of the K- Factor switch is shown in the diagram below: Parameter Switch K factor Switch K Factor Switch Parameter Switch J1: Comms Test J7: Displays J13: Not used J2: To Power Supply J8: Temperature (for J14: Not used Temperature compensation only) J3 : Input from KG Meter J 9 Power for KG Meters J15: Not used Side A J4: Input from KG Meter J10: Totes J16: Not used Side B J5 : Not Used J11: Buzzer J17 Backlighting J6 Not used J12 Nozzle Switches Page 12 of 18

11. Calibration (K-Factor) 11.1 Setting the K-Factor K-Factor is a proportional calibration factor of litres dispensed per revolution of the meter.

13 11. Calibration (K-Factor) 11.1 Setting the K-Factor K-Factor is a proportional calibration factor of litres dispensed per revolution of the meter. To calibrate the dispenser/pump, dispense fuel into a certified measuring container, and compare the display value with the amount dispensed. Example: Display shows True volume To calculate the correct 'K' Factor from the information above; firstly record the existing 'K' Factor. New ' K' Factor Existing ' K' Factor Existing ' Existing ' K' Factor K' Factor Dispensed Amount Displayed Amount Change the existing 'K' Factor to this new value Sealing the K-Factor switch After calibration the K-factor switch should be sealed as shown Page 13 of 18

14 11.3 Standalone Operation In standalone operation, the dispenser will continue working when not connected to a controller. 'Stand-alone' mode being when no authorisation of fills is required and so fills are simply initiated by removing the refuelling assembly from its holder. If standalone operation is inhibited, the dispenser will not work in 'stand-alone' mode, regardless of whether the dispenser is ON LINE to a controller or not. The dispenser ceases to work in 'stand-alone' mode if connected to a controller, regardless of the position of standalone setting. Generally on retail forecourts the dispenser should be set-up for standalone operation. Hence, if the forecourt controller breaks down the dispensers can be set to work in 'stand-alone' mode simply by turning them off then on again. For unattended refuelling sites, the dispensers should not be able to work in 'stand-alone' mode in the event of a controller failure. Therefore the dispenser should be set-up to inhibit standalone operation. This is set in the 'b' code on the K factor switch. The 'b' code to run Standalone without Dispenser Controller is The 'b' code to inhibit Standalone is Pump Controller If the pump is connected to a controller, check that pump data and transaction information is being correctly uploaded to it. Refer to the controller manual for specific instructions regarding connection and setup. 13. Spare Fuses In the event of a fuse blowing on the C4000 Power supply a bag of 3 is included in each flameproof box. Any fuses used from this bag should be replaced Note: There are three different ratings used. If replacing a fuse, ensure that the correct value is used. 14. Precautions if Using Generator Power The power output from onsite generators can cause power spikes that may damage electrical components within the cabinet. When connecting to sites powered by generators, please take the following precautions: 1) Install a power conditioner. Although generators are fitted with power regulators, most are not filtered sufficiently for powering sensitive electrical components. We recommend installing a commercial power conditioner and/or UPS between the generator and the unit. 2) Starting up. Before starting a generator, make sure the power to the unit is turned off. Start the generator, let the generator reach stable operating speed and wait 30 seconds before reconnecting the power to the unit. 3) For units where the generator starts and stops on demand, install a delay timer or PLC to automatically isolate the unit until the operating speed and consistent power output is achieved. 4) Isolate the unit before shutting down the generator. Page 14 of 18

15 15. Error Messages Error Code Fault Action Err 3 No price or pump number set. Set the pump number or: Set a price at the pump or at the controller. Err 7 Excess flow. Max Flowrate exceeded Err 8 Excess reverse rotation of encoder. Check product is not flowing back into the tank once the delivery has finished. Err 9 Faulty or disconnected meter encoder. 1. Check that encoder is plugged in. 2. Replace encoder PCB on meter Err 10 Configuration Lost Reconfigure C4000 refer to C4000 manual Err 12 C4000 memory failure. Change memory IC. F-AD-DS1225 (not applicable to Futra) Ped Abd Display error 1. Check display cable for loose wires/crimps 2. Replace display PCB Page 15 of 18

16. MR160P Spare Parts Commercial display as shown (includes backlighting) F-CP-DISPLAY-CMH Retail display not shown (includes backlighting) F-CP-DISPLAY-GD1H Tote F-BA-TOTE-A-K Nozzle holder

16 16. MR160P Spare Parts Commercial display as shown (includes backlighting) F-CP-DISPLAY-CMH Retail display not shown (includes backlighting) F-CP-DISPLAY-GD1H Tote F-BA-TOTE-A-K Nozzle holder F-NOZL-HLDR-M5SR C4000 microprocessor board F-CP-C4PROCES-A COM125 meter (complete) F-METER-COM125-K COM125 meter (electronics only) F-METER-125/250E Electric motor F-MOTOR W Pump unit F-PUMP-ZYB-50 (incl inlet and outlet gaskets) C4000 power supply (does not include box) F-CP-C4PWR-ASSEM Motor triac F-AT-BTA40-RD91 Also not shown Track 2 cardreader F-BA-CARD-T2C4M Preset (Fascia c/w keypad and interface PCB) F-FAS-PSET-MEM Page 16 of 18

17 17. Product Details Fill in the product details and service agent contact details. Use this information when contacting service agent or help desk. Model number Serial number Date of manufacture Date of installation Software version Equipment connected to the unit Phone number (if dial in site) Merchant ID number (Eftpos site) 18. Contact Details Service Agent Phone Address 1 Address Notes Manufacturer Contact Details The Compac Master Dispenser is designed and manufactured by: Compac Industries Limited 52 Walls Road, Penrose, Auckland 1061, New Zealand P.O. Box , Penrose, Auckland 1641, New Zealand Phone: Fax: Copyright 2015 Compac Industries Limited, All Rights Reserved Contact your service agent in the first instance for any installation issues. Page 17 of 18

18 20. Revision History Previous revision date Summary of changes 22 May May 2010 Added contact details and revision history, updated spare parts 11 Nov 2010 Added tank and pipe information 16 June 2011 Added text The dispensing equipment shall be installed to prevent the delivery hose from contacting the ground when not in use. 06 June 2012 Added Conditions of Use and Installation info. 06 June 2012 Amended Installation Instructions. Generator power, breakaway info. 12 June 2013 Updated wiring information. Added controller information. 5 September 2013 Added sump info in accordance with EPA. File ref. COM Added flange and flexi coupling detail. 27 August 2014 Added front page footer, added outlet size. 13 September 2014 Added outlet height dimension Page 18 of 18

Installation and Setup Instructions

Installation and Setup Instructions Model: Master Version: MMR80-40S Date of issue: 22 May 2009 Compac Industries Ltd P O Box 12-417 Penrose Auckland New Zealand Ph 64 9 5792 094 Fax 64 9 5790 635 www.compac.co.nz